Weaving Control Device for Weft Threading Error Prevention
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Solution Overview
Problem
Weaving machines often experience errors due to incorrect threading of weft threads into weft insertion channel elements, which cannot be detected by prior art control devices, leading to improper weaving patterns and fabric defects.
Innovation Solution
The implementation of a control device that operates weft insertion channel elements in a set-up mode to identify and allocate correct weft insertion channel groups, using detectors and sensors to ensure accurate threading and prevent errors by comparing actual threading configurations with expected ones, and adjusting the weaving sequence accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual threading of weft threads to prewinders is performed, then the weaving machine can be equipped with raw materials, but threading errors occur that cannot be detected
Solution Approach 1:
The control device receives signals from detectors that monitor which weft thread is actually inserted into which weft insertion channel. This feedback information is used to compare the actual threading configuration with the expected configuration, enabling automatic detection and correction of threading errors without requiring manual verification.
Solution Approach 2:
The patent replaces manual visual inspection and mechanical threading verification with an automated detection system using sensors and control logic. The mechanical act of threading is supplemented by an electronic monitoring system that automatically identifies threading errors through detector signals and control device processing.
2Productivity
If threading errors are not detected, then the weaving process continues, but improper weaving patterns and fabric defects occur
Solution Approach 1:
The control device is configured to prevent the weaving process from starting until correct threading is confirmed. By performing the threading verification in advance and blocking the start signal until proper allocation is detected, the system ensures that weaving only begins when threading accuracy requirements are met, preventing fabric defects before they occur.
Solution Approach 2:
The system continuously monitors the allocation of weft threads to insertion channels during setup and provides feedback to the control device. This feedback loop enables real-time verification of threading correctness and automatic adjustment or error signaling before the weaving process commences, ensuring pattern accuracy while maintaining productivity.
3Reliability
If detectors and sensors are added to verify threading, then threading accuracy improves, but device complexity increases
Solution Approach 1:
The control device serves multiple functions: it manages the weaving process, receives detector signals, determines weft thread allocation, compares actual versus expected configurations, and controls the start signal. By making the control device multi-functional rather than adding separate dedicated verification equipment, the patent improves threading reliability without proportionally increasing overall system complexity.
Data Source
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AI summary
The invention relates to an arrangement and a method for optimizing a weaving process comprising a control device (6) and a number of weft insertion channel groups, wherein each weft insertion channel group comprises a first weft insertion channel element (7, 8, 9, 201, 202, 203, 204) and a second weft insertion channel element (11, 12, 13, 41, 42, 43) downstream of the first weft insertion channel element (7, 8, 9, 201, 202, 203, 204),wherein each of the number of first weft insertion channel elements(7, 8, 9, 201,202, 203, 204)is arranged to be operated in a regular mode and in a set-up mode, wherein in the set-up mode upon or after an insertion of weft thread coming from one of the number of first weft insertion channel elements is detected a second weft insertion channel element (11, 12, 13, 41, 42, 43) used for said insertion is identified and prior to operating said first weft insertion channel element in the regular mode, said first weft insertion channel element and said identified second weft insertion channel element used for said insertion are allocated in the control device (6) to one weft insertion channel group.